Water- and energy-saving systems and methods for producing lime-cooked masa

ABSTRACT

Water- and energy-saving systems and methods for producing lime-cooked masa are described. Such methods generally include adding water to maize kernel in a first predetermined proportion, the maize kernel having endosperm, germ, pericarp, and tip cap components. Using a first conditioner, the maize kernel is conditioned for a first predetermined amount of time to cause moisture absorption to within a first predetermined range. The maize kernel is limed. The maize kernel is cooked, using a cooker, in an environment of steam. After the maize kernel is cooked, water is added to the maize kernel in a second predetermined proportion and, using a second conditioner, the maize kernel is conditioned for a second predetermined amount of time to cause moisture absorption to within a second predetermined range. The maize kernel is milled using one or more mills.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/531,553, filed Aug. 5, 2019, which claims the benefit of the filingdate of, and priority to, U.S. Application No. 62/765,075, filed Aug.17, 2018, the entire disclosures of which are hereby incorporated hereinby reference.

TECHNICAL FIELD

The present disclosure relates generally to lime-cooked masa productionand, more particularly, to water- and energy-saving systems and methodsfor producing lime-cooked masa for the preparation of tortilla, snack,and other maize-based foods.

BACKGROUND

Maize, or corn, is a cereal grain. A maize kernel has five separablecomponents, namely tip cap, pericarp (or hull), aleurone, endosperm, andgerm components. Two industrial processes can be employed fortransforming maize into food products, namely wet milling and drymilling. In wet milling processes, maize is separated into relativelypure chemical compound classes of starch, protein, oil, and fiber. Indry milling processes, a reduction in the particle size of clean maizeoccurs with or without separators (for degerming) or aspirators (fordehulling) so that all or some of the original germ and fiber(pericarp/hull) are retained. One type of wet milling process isnixtamal milling (or nixtamalization) in which whole maize kernels aresoaked in a lime solution, cooked, steeped in cooking liquor, drained,and rinsed to yield nejayote (or alkaline steepwater). The process ofnixtamal milling partially removes some of the germ and most of thepericarp. The partially-cooked maize (nixtamal) is then either ground tomake a wet dough (masa) from which tortillas or snack foods can beformed, or is allowed to dry before being milled into masa flour.

The traditional or household preparation of cooking maize with lime atthe rural level requires hard labor and is time consuming (around 14 to20 hours). Most of this time is taken by cooking and steeping/washingoperations; this time can be decreased to 6-12 hours at the urban orcottage level (with 5% to 17% wastewater solid loss). C. Duran-de Bazuaet al., Use of Anaerobic-Aerobic Treatment Systems for Maize ProcessingInstallation: Applied Microbiology In Action, Communicating CurrentResearch and Educational Topics and Trends in Applied Microbiology 3-12(A. Mendez ed., Formatex 2007); Kurt A. Rosentrater et al., EconomicSimulation Modeling of Reprocessing Alternatives for Corn MasaByproducts, 39 Resources, Conservation and Recycling, 341-367 (2003);Ricardo Bressani et al., Fortification of Corn Masa Flour with Ironand/or Other Nutrients: A Literature and Industry Experience Review 4-85(SUSTAIN 1997). In modern processes, lime (0.5% to 1.5% based on grain)is mixed with 1 to 1.5 parts of water for each part of maize. Themixture/suspension is cooked by boiling or steam injection and, whilethe hull/tip cap is partially removed during cooking/washing, there isstill fiber left. After steeping, the alkaline steepwater, whichcontains dissolved hull/aleurone and germ, along with undissolved lime,is discarded. Further, the maize kernels are washed thoroughly ofremaining liquid, so that the residual hulls can be removed manually(for small-scale (<4 tons/day) processes) or mechanically (forlarge-scale (>10 tons/day) nixtamal mills). At the industrial scale(100-500 tons/day), this dehydration step is a major cost factor.

The human food supply chain contributes to 30% of carbon dioxideemissions, but this environmental burden can decrease with clean energytechnology that creates products and services sustainably. Elevatedprices of fossil fuels, such as fuel oil and natural gas (55 kg ofCO₂/MMBTU), allow competition from maize as biofuel (e.g., biomass: 110kg CO₂/MMBTU or ethanol: 70 kg CO₂/MMBTU), which can increasecompetition for food supply and aggravate malnutrition around the world.In addition, costs associated with water usage and its environmentaltreatment affect sustainability in expanding nixtamal mills, especiallyin areas where water is scarce due to increasing climate change(e.g., >2° C. above the pre-industrial average) from CO₂ emissions(e.g., >380 ppmv). It would therefore be desirable to provide a low orzero-carbon energy process for producing lime-cooked masa that wouldcontribute to the stabilization of greenhouse gas concentration byreducing or avoiding energy-related emissions. Moreover, in contrast tothe above-described processes, it would be desirable to provide aprocess for the continuous production of lime-cooked masa that producesno (or negligible) wastewater.

Therefore, what is needed is an apparatus, system, and/or method thataddresses one or more of the foregoing issues, and/or one or more otherissues.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic illustration of a system adapted to makelime-cooked masa, according to one or more embodiments of the presentdisclosure.

FIG. 2 is a flow diagram of a method of making lime-cooked masa usingthe system of FIG. 1 , according to one or more embodiments of thepresent disclosure.

FIG. 3 is a table showing nutritional average compositions forlime-cooked masa (LCM) prepared by the method of FIG. 2 as compared totraditional nixtamal masa (NM) and whole grain maize (WM), according toone or more embodiments of the present disclosure.

FIG. 4 is a table showing the physicochemical content of the lime-cookedmasa (LCM) prepared by the method of FIG. 2 as compared to traditionalnixtamal masa and whole maize dough (WM), according to one or moreembodiments of the present disclosure.

FIG. 5 is a diagrammatic illustration of another system adapted to makelime-cooked masa, according to one or more embodiments of the presentdisclosure.

FIG. 6 is a flow diagram of a method of making lime-cooked masa usingthe system of FIG. 5 , according to one or more embodiments of thepresent disclosure.

FIG. 7 is a table showing nutritional average compositions forlime-cooked masa (LCM) prepared by the method of FIG. 6 as compared totraditional nixtamal masa and whole maize (WM), according to one or moreembodiments of the present disclosure.

FIG. 8 is a table showing the physicochemical content of the lime-cookedmasa (LCM) prepared by the method of FIG. 6 as compared to nixtamalmaize and whole maize dough, according to one or more embodiments of thepresent disclosure.

FIG. 9 is a diagrammatic illustration of yet another system adapted tomake lime-cooked masa, according to one or more embodiments of thepresent disclosure.

FIG. 10 is a flow diagram of a method of making lime-cooked masa usingthe system of FIG. 9 , according to one or more embodiments of thepresent disclosure.

FIG. 11 is a table comparing water and energy consumption, as well assolid waste and wastewater, between traditional masa production andlime-cooked masa prepared using one or more embodiments of the presentdisclosure.

FIG. 12 is a diagrammatic illustration of a computing node forimplementing one or more embodiments of the present disclosure.

DETAILED DESCRIPTION

The present disclosure provides a process that departs from existingnixtamalization processes for whole cereal grains such as, for example,maize, to produce lime-cooked masa. This process involves athermo-alkaline treatment that produces no (or negligible) wastewaterwith reduced steam heating consumption, while producing a high yield ofthe desired food product. In some embodiments, one objective is toemploy an industrial process with an atmospheric steamer to continuouslyproduce cooked coarse-sized and fine-sized dough fractions and also toyield a wasteless or a reduced waste lime-cooked masa. In someembodiments, another objective is to provide a lime-cooked masa fortortillas and snacks that is uniform and improved in its nutritional andphysico-chemical properties.

In an embodiment, as illustrated in FIG. 1 , a system adapted to makelime-cooked masa is generally referred to by the reference numeral 100.The system 100 includes a moisturizer such as, for example, a mixer 105.A conditioner 110 is operably coupled to the mixer 105. A blower 115 isoperably coupled to a boiler 120. A cooker such as, for example, asteamer 125, is operably coupled to the boiler 120. The steamer 125 isalso operably coupled to the conditioner 110. A conditioner such as, forexample, a quencher 130, is operably coupled to the steamer 125. Mills135 and 140 are each operably coupled to the quencher 130. A cooler 145is operably coupled to each of the mills 135 and 140. A kneader 150 isoperably coupled to the cooler 145. A sheet cutter 155 is operablycoupled to the kneader 150. An oven 160 is operably coupled to the sheetcutter 155. A cooler such as, for example, a homogenizer cooler 165, isoperably coupled to the oven 160. A toaster/fryer 170 is operablycoupled to the homogenizer cooler 165. In some embodiments, thetoaster/fryer 170 includes a fryer and a cooling section (not shown)located downstream of the fryer; in some embodiments, the coolingsection of the toaster/fryer 170 is, or includes, one or more clean airfans. A packer 175 is operably coupled to each of the homogenizer cooler165 and the toaster/fryer 170.

In operation, with continuing reference to FIG. 1 , the mixer 105receives clean maize kernel, as indicated by arrow 180, receives a limesolution containing water and lime, as indicated by arrow 185, limes thereceived clean maize by mixing the received clean maize kernel with thereceived lime solution, and discharges the mixture, as indicated byarrow 190. In some embodiments, the mixture of the received clean maizekernel and the received lime solution contains 0.1-0.3% by weight limeto maize kernel. On a dry weight basis, the maize kernel has tip cap(e.g., 0.8-1.1% by weight), pericarp/hull (e.g., 5.1-5.7% by weight),aleurone (2% by weight), endosperm (e.g., 81.1-83.5% by weight), andgerm (e.g., 10.2-11.9% by weight). The pericarp contains 90% insolublefiber (e.g., 67% hemicellulose-heteroxylans, 23% cellulose, 5-7%glucuronic acid, and 0.1% lignin). Stanley A. Watson, Description,Development, Structure and Composition of the Corn Kernel, Corn:Chemistry and Technology 69-106 (Pamela J. White & Lawrence A. Johnsoneds., American Association of Cereal Chemists, Inc. 2nd ed. 2003); F. R.Earle et al., Composition of the Components Parts of the Maize Kernel,23 Cereal Chemistry, 504-511 (1946).

The conditioner 110 receives the mixture discharged from the mixer 105,as indicated by the arrow 190, tempers the mixture causing additionalmoisture absorption, and discharges the tempered mixture, as indicatedby arrow 195. In some embodiments, the conditioner 110 includes a feederadapted to receive the mixture discharged from the mixer 105. In someembodiments, as in FIG. 1 , water is added to the mixture dischargedfrom the mixer 105, as indicated by arrow 200, before, during, or afterthe discharged mixture is received by the conditioner 110.

The blower 115 blows clean air to the boiler 120, as indicated by arrows205 and 210, and the boiler 120, in turn, receives water, as indicatedby arrow 215, receives the clean air from the blower 115, as indicatedby the arrow 210, receives fuel (e.g., natural gas), as indicated byarrow 220, boils the received water by burning the received fuel andclean air, vents exhaust from the burnt fuel, as indicated by arrow 225,and discharges steam produced by the boiled water, as indicated by arrow230.

The steamer 125 receives the tempered mixture discharged from theconditioner 110, as indicated by the arrow 195, receives the steamdischarged from the boiler 120, as indicated by the arrow 230, precooksthe received mixture with the received steam, and discharges theprecooked mixture, as indicated by arrow 235. In some embodiments, thesteamer 125 is or includes a rotary cylinder chamber and/or aheat-transfer screw conveyer. In some embodiments, the steamer 125includes a feeder adapted to receive the tempered mixture from theconditioner 110. As described herein, steaming is a thermal process bywhich food is heated for the purpose of inactivating enzymes, modifyingtexture, and/or preserving color, flavor, and nutritional value. Hotwater and steam can be used as heating media, but hot gas (dry-heat) canalso be used. Steam infusion heating is a direct-contact process wherecondensation occurs on the surface of a flowable food, under atmosphericpressure. This process requires atmospheric steam, pumpable food andmechanical device to facilitate steam heating/condensation.

The quencher 130 receives the precooked mixture discharged from thesteamer 125, as indicated by the arrow 235, tempers the precookedmixture causing cooling and additional moisture absorption, anddischarges the tempered mixture, as indicated by arrows 240 a and 240 b.In some embodiments, the quencher 130 includes a feeder adapted toreceive the precooked mixture discharged from the steamer 125. In someembodiments, as in FIG. 1 , water is added to the precooked mixturedischarged from the steamer 125, as indicated by arrow 245, before,during, or after the precooked mixture is received by the quencher 130.

The mill 135 receives at least a first portion of the tempered mixturedischarged from the quencher 130, as indicated by the arrow 240 a,grinds the first portion into the fine-ground dough material, anddischarges the fine-ground dough material, as indicated by arrow 250 a.In some embodiments, the mill 135 includes a feeder adapted to receivethe first portion of the tempered mixture discharged from the quencher130. In some embodiments, the mill 135 is a gravity-fed attrition mill(e.g., a stone mill or gap mill). In some embodiments, a stone gap inthe mill 135 measures 1,000 microns. Similarly, the mill 140 receives atleast a second portion of the tempered mixture discharged from thequencher 130, as indicated by the arrow 240 b, grinds the second portioninto the coarse-ground dough material, and discharges the coarse-grounddough material, as indicated by arrow 250 b. In some embodiments, themill 140 includes a feeder adapted to receive the second portion of thetempered mixture discharged from the quencher 130. In some embodiments,the mill 140 is a gravity-fed attrition mill (e.g., a stone mill or gapmill). In some embodiments, a stone gap in the mill 140 measures 2,000microns. In some embodiments, as in FIG. 1 , water is added to thetempered mixture discharged from the quencher, as indicated by arrow255, before, during, or after the tempered mixture is received by themill 135 or the mill 140.

The cooler 145 receives the fine-ground dough material from the mill135, as indicated by the arrow 250 a, receives the coarse-ground doughmaterial from the mill 140, as indicated by the arrow 250 b, receivesclean air (e.g., discharged from the blower 115), as indicated by arrow260, cools the received dough materials with the received clean air, anddischarges the cooled dough materials, as indicated by arrow 265. Insome embodiments, the cooler 145 includes a belt conveyor adapted toreceive the fine-ground dough material from the mill 135, and to receivethe coarse-ground dough material from the mill 140.

The kneader 150 receives the cooled dough materials discharged from thecooler 145, as indicated by the arrow 265, mixes the cooled doughmaterials into a lime-cooked masa, and discharges the lime-cooked masa,as indicated by arrow 270.

The sheet cutter 155 receives the lime-cooked masa from the kneader 150,as indicated by the arrow 270, forms the lime-cooked masa into sheets,cuts individual pieces from the sheets, and discharges the individualpieces, as indicated by arrow 275.

The oven 160 receives the individual pieces discharged from the sheetcutter 155, as indicated by the arrow 275, bakes the received individualpieces, and discharges the baked individual pieces, as indicated byarrow 280. In some embodiments, the oven 160 is a three-tiered,gas-fired oven.

The homogenizer cooler 165 receives the baked individual piecesdischarged from the oven, as indicated by the arrow 280, cools andhomogenizes moisture of the baked individual pieces, and discharges thecooled individual pieces, as indicated by arrow 285. In someembodiments, the homogenizer cooler 165 includes a series of open tiers.

In some embodiments, the packer 175 receives the cooled individualpieces discharged from the homogenizer cooler 165, as indicated by thearrow 285, packages the cooled individual pieces in snack- ortortilla-sized portions, and discharges the packaged portions, asindicate by arrows 290 a and/or 290 b. In addition, or instead, thetoaster/fryer 170 may receive at least a portion of the cooledindividual pieces discharged from the homogenizer cooler 165, asindicated by arrow 295, fry the cooled individual pieces and cool themagain in the cooling section of the toaster/fryer 170, and discharge thefried individual pieces, as indicated by arrow 300. In such instances,the packer 175 receives the fried individual pieces discharged from thetoaster/fryer 170, as indicated by the arrow 300, packages the friedindividual pieces in snack- or tortilla-sized portions, and dischargesthe packaged portions, as indicated by the arrows 290 a and/or 290 b.

In an embodiment, as illustrated in FIG. 2 , a method of makinglime-cooked masa using the system 100 is generally referred to by thereference numeral 305. The method 305 includes at a step 310, mixing,using the mixer 105, maize kernel with lime solution to lime the maizekernel. In some embodiments, the mixture contains 0.1-0.3% by weightlime to maize kernel. In some embodiments, the maize kernel isdry-cleaned prior to mixing with the lime solution. The maize kernel maybe a maize grain such as, for example, Zea Mays subspecies Parviglumisor Mexicana (e.g., white maize, yellow maize, blue maize,quality-protein maize, waxy maize, and/or high-amylose maize) or anothercereal grain. The lime solution may contain 1% to 5% lime by weight; forexample, the lime solution may contain 2% to 3% lime by weight. Thecleaned maize kernel is thoroughly sprayed with the lime solution for 5to 10 minutes to uniformly wet the kernel surface. In some embodiments,a solid to water ratio from 1:0.04 to 1:0.07 is maintained in the mixer105 during the step 310. As a result, the moisture content of the maizekernel is adjusted from 12% or 13% to 17% or 18% during the step 310.

At a step 315, the conditioner 110 tempers the mixture to causeadditional moisture absorption. In some embodiments, the mixture istempered for 20 to 40 minutes at temperatures from 25° C. to 30° C.Water is added to the mixture before and/or during the tempering of themixture by the conditioner 110. More particularly, in some embodiments,a solid to water ratio from 1:0.13 to 1:0.19 is maintained in theconditioner 110 during the step 315. As a result, the moisture contentof the maize kernel is adjusted to 25% to 30% during the step 315; forexample, the moisture content of the maize kernel may be adjusted to 28%to 30%.

At a step 320, the steamer 125 precooks the tempered mixture with steam(e.g., saturated steam). In some embodiments, the tempered mixture isprecooked for 5 to 10 minutes at temperatures from 80° C. to 95° C. andat steam pressures from 90 kPa to 110 kPa (or 13.1-16.0 psi); forexample, the tempered mixture may be precooked at a steam pressure of101 kPa (or 14.7 psi) for a desired time to control temperature. As aresult, the tempered mixture is heated and rehydrated (i.e., from steamcondensate), and the moisture content of the maize kernel is adjusted to30% to 42%; for example, the moisture content of the maize kernel may beadjusted to 32% to 38%; for another example, the moisture content of themaize kernel may be adjusted to 34% to 36%. In some embodiments,execution of the step 320 causes hydrolysis of the external-most layersof the maize kernel (i.e., the pericarp, the tip cap, and the aleurone)and partial hydrolysis or gelatinization of the internal-most layers ofthe maize kernel (i.e., the endosperm and the germ). As a result, thebran (i.e., the pericarp and the tip cap) is preserved so that thecalcium bound in the resulting lime-cooked masa is increased for humannutrition (as compared to nixtamal masa and whole maize).

At a step 325, the quencher 130 tempers the precooked mixture to causecooling and additional moisture absorption through the bran (i.e., thepericarp and tip cap). In some embodiments, the precooked mixture istempered for 30 to 60 minutes at temperatures from 65° C. to 80° C.Water is added to the precooked mixture before and/or during temperingof the precooked mixture by the quencher 130. More particularly, in someembodiments, a solid to water ratio from 1:0.06 to 1:0.24 is maintainedin the quencher 130 during the step 325. As a result, the moisturecontent of the maize kernel is adjusted to 35% to 47% during the step325; for example, the moisture content of the maize kernel may beadjusted to 39% to 41%. Once tempered, the kernel is hard enough to bemilled more efficiently than higher moisture and more elastic grains,while maintaining sufficient elasticity to avoid overheating duringmilling (which can cause starch damage in masa products).

At a step 330, the mill 135 grinds a first portion of the temperedmixture into a fine-ground dough material. Similarly, at a step 335, themill 140 grinds a second portion of the tempered mixture into acoarse-ground dough material. Water is added to the tempered mixturebefore and/or during the grinding of the first and second portions bythe respective mills 135 and 140. More particularly, in someembodiments, a solid to water ratio from 1:0.12 to 1:0.27 is maintainedin the respective mills 135 and 140 during the steps 330 and 335. As aresult, the moisture content of the maize kernel is adjusted to 40% to52% during the steps 330 and 335; for example, the moisture content ofthe maize kernel may be adjusted to 44% to 46%. In addition, the addedwater cools the grinding stones of the respective mills 135 and 140 totemperatures from 45° C. to 60° C. During the steps 330 and 335, themills 135 and 140 grind and abrade the first and second portions of thetempered mixture into a coarse-ground (larger-sized) fraction and afine-ground (smaller-sized) fraction. The coarse-ground fraction (e.g.,14-35 mesh) may be used to produce snacks. The fine-ground fraction(e.g., 45-100 mesh) may be used to produce lime-cooked tortilla. Bimodalparticle size distribution of the coarse-ground and fine-groundfractions is directly related to the respective sizes of the stone gapsin the mills 135 and 140, the pressure between the respective rotor andstator stones of the mills 135 and 140, the relative surface velocitiesof the respective rotor and stator stones of the mills 135 and 140,and/or the apparent viscosity of the desired end product.

At a step 340, the cooler 145 cools the fine-ground and coarse-grounddough materials with clean air (e.g., supplied from the blower 115). Insome embodiments, the dough materials are cooled for 5 minutes. As aresult, the moisture content of the dough materials is adjusted to 38%to 50% during the step 340; for example, the moisture content of thedough materials may be adjusted to 42% to 45%.

At a step 345, the kneader 150 mixes the cooled dough materials togetherto form a lime-cooked masa. In some embodiments, the lime-cooked masa isuniformly mixed, plastic (elastic), and cohesive (viscous).

At a step 350, the sheet cutter 155 forms the lime-cooked masa intosheets and cuts individual pieces (e.g., disk- or triangular-shaped)from the sheets. In some embodiments, the sheets are cut into theindividual pieces by a rotating cutter.

At a step 355, the oven 160 bakes the individual pieces. In someembodiments, the individual pieces are baked for 20 to 40 seconds attemperatures from 280° C. to 300° C.

At a step 360, the homogenizer cooler 165 cools the baked individualpieces (e.g., with clean air supplied from the blower 115).

At a step 365, the packer 175 packages the cooled individual pieces insnack- or tortilla-sized portions. In some embodiments, the cooledindividual pieces are packaged in the tortilla-sized portions with amoisture content 40% to 50%. In other embodiments, the toaster/fryer 170bakes or fries the cooled individual pieces before the packer 175packages the baked or fried individual pieces in the snack-sizedportions. For example, the cooled individual pieces may be baked for 35to 50 seconds at temperatures from 260° C. to 290° C., or fried (e.g.,in vegetable oil) for 50 to 80 seconds at temperatures from 170° C. to190° C. The baked or fried individual pieces are then packaged (e.g.,laminated in plastic bags) in the snack-sized portions (e.g., as wholesnacks) with a moisture content of less than 1.5%.

Turning to FIG. 3 , a table showing nutritional average compositions forlime-cooked masa prepared by the method 305 (“LCM1”), nixtamal masa(“NM”), and whole maize (“WM”) is illustrated; composition values shownin the table are based on a moisture content of 10%. The LCM1 and the NMeach include a network of solubilized starch and non-starch polymers(continuous phase) supporting dispersed, uncooked, and swollenprotein-starch granules, fiber cell fragments, and lipids (dispersedphase). Both the LCM1 and the NM contain particles from the endospermand the germ; however, the LCM1 and the NM contain different contentfrom the bran (i.e., the pericarp and the tip cap). Consequently, asshown in FIG. 3 , the LCM1 contains 10.4% dietary fiber and 0.15%calcium. Moreover, the LCM1 has, on average, a higher nutritional valueas compared to the NM, with more protein (at ˜9%), ˜25% more fat, ˜30%more dietary fiber, ˜100% more crude fiber, and ˜25% more resistantstarch. Dietary fiber may be described as a carbohydrate polymer withten or more monomeric units (which are not hydrolyzed by the endogenousamylases in the small intestine) belonging to one of three categories:(i) naturally occurring edible carbohydrates in consumed food; (ii)carbohydrates obtained from raw food by physical, chemical, or enzymatictreatments and which have been shown to physiologically benefit health;and (iii) synthetic carbohydrates with a (claimed) health benefit.Prebiotic resistant starch (RS3: retrograded after heat-cool cycles) isincluded in this definition because it is obtained from maize andpartially fermented by colonic bacteria.

In some embodiments, due to the inclusion of, or similarities to, otherminimal processing techniques in the production of the LCM1 (e.g.,cracking, crushing, rolling, lightly pearling, and/or steaming), theLCM1 is considered “whole grain”. Other benefits associated with theLCM1 include, but are not limited to, organoleptic benefits (e.g.,improved flavor and texture for tortillas) and other nutritionalbenefits (e.g., unbound niacin for pellagra prevention, bound calciumfor osteoporosis, etc.). For example, the functional gum-like dispersionof the LCM1 (from 0.3% to 0.4% acidic soluble fiber) may impart not onlya high water-binding capacity and viscosity, but also yields abiofunctional treatment for osteoporosis. Moreover, the LCM1 hasimproved tortilla texture and higher calcium availability (associatedwith bran acidic groups).

Turning to FIG. 4 , a table showing the physico-chemical content of theLCM1 (i.e., prepared by the method 305), the NM, and the WM (i.e.,dry-milled dough) is illustrated. On a percentage-by-weight basis, boththe LCM1 and the NM have bimodal distributions containing a smaller- anda larger-sized group of particles as described by their modes. Moreparticularly, the LCM1 yields a larger-sized mode (i.e., 18 mesh or1,000 microns with 15% weight) and a smaller-sized mode (i.e., 60 meshor 250 microns and 35% weight) appropriate for tortilla and snackmaking. The NM also yields a larger-sized mode (i.e., 35 mesh or 500microns and 30% weight) and a smaller-sized mode (i.e., 80 mesh or 180microns and 20% weight). However, as compared to the NM dough (at ˜60%),the LCM1 dough has a lower weight fraction (˜33%) above 45 mesh or 355microns. The difference in size and weight between the larger-sized modeof the LCM1 and the larger-sized mode of the NM causes the apparent peakviscosity of the LCM1 (˜2,760 centipoise) (at 95° C.) to be lower thanthe apparent peak viscosity of the NM (˜3,470 centipoise). Thisdifference in apparent peak viscosity may be (at least partially)attributable to: free starch particles increasing the viscosity of theNM during pasting (i.e., at 14% solids content); and slower waterdiffusion into, and swelling of, the LCM1's coarser particles. Finally,the WM contains smaller and finer particles (i.e., 355 microns) thanboth the LCM1 and the NM; as a result, the WM has an even higherapparent peak viscosity (˜5,600 centipoise).

In an embodiment, as illustrated in FIG. 5 , another system adapted tomake lime-cooked masa is generally referred to by the reference numeral370. The system 370 includes several components substantially identicalto corresponding components of the system 100, which substantiallyidentical components are given the same reference numerals. However, thesystem 370 also includes several components that are different fromcomponents of the system 100; more particularly, the system 370 does notinclude the mills 135 and 140, but instead includes a crusher 375, aseparator 380, and a mill 385. Accordingly, as shown in FIG. 5 , thesystem 370 includes the mixer 105, to which the conditioner 110 isoperably coupled. The steamer 125 is operably coupled to the conditioner110. The boiler 120 is operably coupled to the steamer 125. The blower115 is operably coupled to the boiler 120. The quencher 130 is operablycoupled to the steamer 125. The crusher 375 is operably coupled to thequencher 130. The separator 380 is operably coupled to the crusher 375.The mill 385 is operably coupled to the separator 380. The cooler 145 isoperably coupled to the mill 385. The kneader 150 is operably coupled tothe cooler 145. The sheet cutter 155 is operably coupled to the kneader150. The oven 160 is operably coupled to the sheet cutter 155. Thehomogenizer cooler 165 is operably coupled to the oven 160. Thetoaster/fryer 170 is operably coupled to the homogenizer cooler 165. Asnoted above, in some embodiments, the toaster/fryer 170 includes a fryerand a cooling section (not shown) located downstream of the fryer; insome embodiments, the cooling section of the toaster/fryer 170 is, orincludes, one or more clean air fans. The packer 175 is operably coupledto each of the homogenizer cooler 165 and the toaster/fryer 170.

In operation, with continuing reference to FIG. 5 , the mixer 105receives the clean maize kernel, as indicated by arrow 390, receives thelime solution containing the water and lime, as indicated by arrow 395,limes the received clean maize kernel by mixing the received clean maizekernel with the received lime solution, and discharges the mixture, asindicated by arrow 400. In some embodiments, the mixture of the receivedclean maize kernel and the received lime solution contains 0.1-0.3% byweight lime to maize kernel.

The conditioner 110 receives the mixture discharged from the mixer 105,as indicated by the arrow 400, tempers the mixture causing additionalmoisture absorption, and discharges the tempered mixture, as indicatedby arrow 405. In some embodiments, as in FIG. 5 , water is added to themixture discharged from the mixer 105, as indicated by arrow 410,before, during, or after the discharged mixture is received by theconditioner 110.

The blower 115 blows clean air to the boiler 120, as indicated by arrows415 and 420, which boiler 120, in turn, receives water, as indicated byarrow 425, receives the clean air from the blower 115, as indicated bythe arrow 420, receives fuel (e.g., natural gas), as indicated by arrow430, boils the received water by burning the received fuel and cleanair, vents exhaust from the burnt fuel, as indicated by arrow 435, anddischarges steam produced by the boiled water, as indicated by arrow440.

The steamer 125 receives the tempered mixture discharged from theconditioner 110, as indicated by the arrow 405, receives the steamdischarged from the boiler 120, as indicated by the arrow 440, precooksthe received mixture with the received steam, and discharges theprecooked mixture, as indicated by arrow 445.

The quencher 130 receives the precooked mixture discharged from thesteamer 125, as indicated by the arrow 445, tempers the precookedmixture causing cooling and additional moisture absorption, anddischarges the tempered mixture, as indicated by arrow 450. In someembodiments, as in FIG. 5 , water is added to the precooked mixturedischarged from the steamer 125, as indicated by arrow 455, before,during, or after the precooked mixture is received by the quencher 130.

The crusher 375 receives the tempered mixture discharged from thequencher 130, as indicated by the arrow 450, crushes the temperedmixture into a coarse-ground kernel portion and a hull (or pericarp)portion, and discharges the coarse-ground kernel portion and the hullportion, as indicated by arrow 460. In some embodiments, the crusher 375includes a feeder adapted to receive the tempered mixture dischargedfrom the quencher 130. In some embodiments, the crusher 375 is agravity-fed attrition mill (e.g., a jaw or rotary crusher). In someembodiments, a stone gap in the crusher 375 measures from 3,000 micronsto 4,000 microns.

The separator 380 receives the coarse-ground kernel portion and the hullportion discharged from the separator 380, as indicated by the arrow460, separates the coarse-ground kernel portion from the hull portion,and discharges the separated coarse-ground kernel portion, as indicatedby arrow 465, and the separated hull portion, as indicated by arrow 470.In some embodiments, the separator 380 at least partially separates thecoarse-ground kernel portion from the hull portion by receiving cleanair (e.g., discharged from the blower 115), as indicated by arrow 475,aspirating the received hull portion with the received clean air, andventing the aspirated air from the hull portion, as indicated by arrow480. In addition, or instead, the separator 380 may include a sieveadapted to at least partially separate the coarse-ground kernel portionfrom the hull portion.

The mill 385 receives the separated coarse-ground kernel portiondischarged from the separator 380, as indicated by the arrow 465, grindsthe separated coarse-ground kernel portion into dough materials, anddischarges the dough materials, as indicated by arrow 485. In someembodiments, the mill 385 includes a feeder adapted to receive theseparated coarse-ground kernel portion discharged from the separator380. In some embodiments, as in FIG. 5 , water is added to the separatedcoarse-ground kernel portion discharged from the separator 380, asindicated by arrow 486, before, during, or after the separatedcoarse-ground kernel portion is received by the mill 385. In someembodiments, the mill 385 is a gravity-fed attrition mill (e.g., a stonemill or gap mill). In some embodiments, a stone gap in the mill 385measures from 300 microns to 1,500 microns.

The cooler 145 receives the dough materials from the mill 385, asindicated by the arrow 485, receives clean air (e.g., discharged fromthe blower 115), as indicated by arrow 490, cools the received doughmaterials with the received clean air, and discharges the cooled doughmaterials, as indicated by arrow 495. In some embodiments, the cooler145 includes a band conveyer adapted to receive the dough materialsdischarged from the mill 385.

The kneader 150 receives the cooled dough materials discharged from thecooler 145, as indicated by the arrow 495, mixes the cooled doughmaterials into a lime-cooked masa, and discharges the lime-cooked masa,as indicated by arrow 500.

The sheet cutter 155 receives the lime-cooked masa from the kneader 150,as indicated by the arrow 500, forms the lime-cooked masa into sheets,cuts individual pieces from the sheets, and discharges the individualpieces, as indicated by arrow 505.

The oven 160 receives the individual pieces discharged from the sheetcutter 155, as indicated by the arrow 505, bakes the received individualpieces, and discharges the baked individual pieces, as indicated byarrow 510.

The homogenizer cooler 165 receives the baked individual piecesdischarged from the oven, as indicated by the arrow 510, homogenizesmoisture and cools the baked individual pieces, and discharges thecooled individual pieces, as indicated by arrow 515.

In some embodiments, the packer 175 receives the cooled individualpieces discharged from the homogenizer cooler 165, as indicated by thearrow 515, packages the cooled individual pieces in snack- ortortilla-sized portions, and discharges the packaged portions, asindicate by arrows 520 a and/or 520 b. In addition, or instead, thetoaster/fryer 170 may receive at least a portion of the cooledindividual pieces discharged from the homogenizer cooler 165, asindicated by arrow 525, fry the cooled individual pieces, cool theindividual pieces again in the cooling section of the toaster/fryer 170,and discharge the fried individual pieces, as indicated by arrow 530. Insuch instances, the packer 175 receives the fried individual piecesdischarged from the toaster/fryer 170, as indicated by the arrow 530,packages the fried individual pieces in snack- or tortilla-sizedportions, and discharges the packaged portions, as indicated by thearrows 520 a and/or 520 b.

In an embodiment, as illustrated in FIG. 6 , a method of makinglime-cooked masa using the system 100 is generally referred to by thereference numeral 535. The method 535 includes at a step 540, mixing,using the mixer 105, maize kernel with lime solution to lime the maizekernel. In some embodiments, the mixture contains 0.1-0.3% by weightlime to maize kernel. In some embodiments, the maize kernel isdry-cleaned prior to mixing with the lime solution. The maize kernel maybe a maize grain such as, for example, Zea Mays subspecies Parviglumisor Mexicana (e.g., white maize, yellow maize, blue maize,quality-protein maize, waxy maize, and/or high-amylose maize) or anothercereal grain. The lime solution may contain 1% to 5% lime by weight; forexample, the lime solution may contain 2% to 3% lime by weight. Thecleaned maize kernel is thoroughly sprayed with the lime solution for 5to 10 minutes to uniformly wet the kernel surface. In some embodiments,a solid to water ratio from 1:0.04 to 1:0.07 is maintained in the mixer105 during the step 540. As a result, the moisture content of the maizekernel is adjusted from 12% or 13% to 17% or 18% during the step 540.

At a step 545, the conditioner 110 tempers the mixture to causeadditional moisture absorption. In some embodiments, the mixture istempered for 20 to 40 minutes at temperatures from 25° C. to 30° C.Water is added to the mixture before and/or during the tempering of themixture by the conditioner 110. More particularly, in some embodiments,a solid to water ratio from 1:0.10 to 1:0.18 is maintained in theconditioner 110 during the step 545. As a result, the moisture contentof the maize kernel is adjusted to 25% to 30% during the step 545; forexample, the moisture content of the maize kernel may be adjusted to 28%to 30%.

At a step 550, the steamer 125 precooks the tempered mixture with steam(e.g., saturated steam). In some embodiments, the tempered mixture isprecooked for 5 to 10 minutes at temperatures from 80° C. to 95° C. andat steam pressures from 90 kPa to 110 kPa (or 13.1-16.0 psi); forexample, the tempered mixture may be precooked at a steam pressure of101 kPa (or 14.7 psi) for a desired time to control temperature. As aresult, the tempered mixture is heated and rehydrated (i.e., from steamcondensate), and the moisture content of the maize kernel is adjusted to30% to 42%; for example, the moisture content of the maize kernel may beadjusted to 32% to 38%; for another example, the moisture content of themaize kernel may be adjusted to 34% to 36%. In some embodiments,execution of the step 550 causes hydrolysis of the external-most layersof the maize kernel (i.e., the pericarp, the tip cap, and the aleurone)and partial hydrolysis or gelatinization of the internal-most layers ofthe maize kernel (i.e., the endosperm and the germ). As a result, thebran (i.e., the pericarp and the tip cap) is preserved so that thecalcium bound in the resulting lime-cooked masa is increased for humannutrition (as compared to nixtamal masa and whole maize).

At a step 555, the quencher 130 tempers the precooked mixture to causecooling and additional moisture absorption through the bran (i.e., thepericarp and tip cap). In some embodiments, the precooked mixture istempered for 30 to 60 minutes at temperatures from 65° C. to 80° C.Water is added to the precooked mixture before and/or during temperingof the precooked mixture by the quencher 130. More particularly, in someembodiments, a solid to water ratio from 1:0.11 to 1:0.16 is maintainedin the quencher 130 during the step 555. As a result, the moisturecontent of the maize kernel is adjusted to 35% to 47% during the step555; for example, the moisture content of the maize kernel may beadjusted to 39% to 41%. Once tempered, the kernel is hard enough to bemilled more efficiently than higher moisture and more elastic grains,while maintaining sufficient elasticity to avoid overheating duringmilling (which can cause starch damage in masa products).

At a step 560, the crusher 375 crushes the tempered mixture into acoarse-ground kernel portion and a hull portion.

At a step 565, the separator 380 separates the coarse-ground kernelportion from the hull portion. In some embodiments, the separated hullportion makes up between 5% to 6% by weight of the coarse-ground kernelportion and the hull portion, taken together.

At a step 570, the mill 385 grinds the separated coarse-ground kernelportion into dough materials. Water is added to the separatedcoarse-ground kernel portion before and/or during the grinding of theseparated coarse-ground kernel portion by the mill 385. Moreparticularly, in some embodiments, a solid to water ratio from 1:0.14 to1:0.20 is maintained in the mill 385 during the step 570. As a result,the moisture content of the maize kernel is adjusted to 40% to 52%during the step 570; for example, the moisture content of the maizekernel may be adjusted to 44% to 46%. In addition, the added water coolsthe grinding stones of the mill 385 to temperatures from 45° C. to 60°C. During the step 570, the mill 385 grinds and abrades thecoarse-ground kernel portion into a coarse-ground (larger-sized)fraction and a fine-ground (smaller-sized) fraction. The coarse-groundfraction (e.g., 14-35 mesh) may be used to produce snacks. Thefine-ground fraction (e.g., 45-100 mesh) may be used to producelime-cooked tortilla. Bimodal particle size distribution of thecoarse-ground and fine-ground fractions is directly related to the sizeof the stone gap in the mill 385, the pressure between the respectiverotor and stator stones of the mill 385, and/or the relative surfacevelocities of the respective rotor and stator stones of the mill 385. Inaddition, or instead, the bimodal particle size distribution of thecoarse-ground and fine-ground fractions may be directly related to thesize of the stone gap in the crusher 375, the pressure between therespective rotor and stator stones of the crusher 375, and/or therelative surface velocities of the respective rotor and stator stones ofthe crusher 375.

At a step 575, the cooler 145 cools the fine-ground and coarse-groundfractions with clean air (e.g., supplied from the blower 115). In someembodiments, the dough materials are cooled for 5 minutes. As a result,the moisture content of the dough materials is adjusted to 38% to 50%during the step 575; for example, the moisture content of the doughmaterials may be adjusted to 42% to 45%.

At a step 580, the kneader 150 mixes the cooled dough materials togetherto form a lime-cooked masa. In some embodiments, the lime-cooked masa isuniformly mixed, plastic (elastic), and cohesive (viscous).

At a step 585, the sheet cutter 155 forms the lime-cooked masa intosheets and cuts individual pieces (e.g., disk- or triangular-shaped)from the sheets. In some embodiments, the sheets are cut into theindividual pieces by a rotating cutter.

At a step 590, the oven 160 bakes the individual pieces. In someembodiments, the individual pieces are baked for 20 to 40 seconds attemperatures from 280° C. to 300° C.

At a step 595, the homogenizer cooler 165 cools the baked individualpieces (e.g., with clean air to homogenize and balance moisture).

At a step 600, the packer 175 packages the cooled individual pieces insnack- or tortilla-sized portions. In some embodiments, the cooledmoisture equilibrated individual pieces are packaged in thetortilla-sized portions with a moisture content 40% to 50%. In otherembodiments, the toaster/fryer 170 fries the cooled moistureequilibrated individual pieces and then cools the hot fried individualpieces before the packer 175 packages the fried individual pieces in thesnack-sized portions. For example, the moisture equilibrated cooledindividual pieces may be fried (e.g., in vegetable oil) for 50 to 80seconds at temperatures from 170° C. to 190° C. The hot fried individualpieces are then cooled in the cooling section of the toaster/fryer 170,and then are packaged (e.g., laminated in plastic bags) in thesnack-sized portions (e.g., as whole snacks) with a moisture content ofless than 1.5%.

Turning to FIG. 7 , a table showing nutritional average compositions forlime-cooked masa prepared by the method 535 (“LCM2”), nixtamal masa(“NM”), and whole maize (“WM”) is illustrated; composition values shownin the table are based on a moisture content of 10%. The LCM2 and the NMeach include a network of solubilized starch and non-starch polymers(continuous phase) supporting dispersed, uncooked, and swollenprotein-starch granules, fiber cell fragments, and lipids (dispersedphase). Both the LCM2 and the NM contain particles from the endospermand the germ; however, the LCM2 and the NM contain different contentfrom the bran (i.e., the pericarp and the tip cap). Consequently, asshown in FIG. 7 , the LCM2 contains 8.5% dietary fiber and 0.1% calcium.Moreover, the LCM2 has, on average, a higher nutritional value ascompared to the NM, with more protein (at ˜9%), ˜25% more fat, and ˜25%more resistant starch.

In some embodiments, due to the inclusion of, or similarities to, otherminimal processing techniques in the production of the LCM2 (e.g.,cracking, crushing, rolling, lightly pearling, and/or steaming), theLCM2 is considered “whole grain”. Other benefits associated with theLCM2 include, but are not limited to, organoleptic benefits (e.g.,improved flavor and texture for tortillas) and other nutritionalbenefits (e.g., unbound niacin for pellagra prevention, bound calciumfor osteoporosis, etc.). For example, the functional gum-like dispersionof the LCM2 (from 0.2% to 0.3% acidic soluble fiber) may impart not onlya high water-binding capacity and viscosity, but also yields abiofunctional treatment for osteoporosis. Moreover, the LCM2 hasimproved tortilla texture and higher calcium availability (associatedwith bran acidic groups).

Turning to FIG. 8 , a table showing the physico-chemical content of theLCM2 (i.e., prepared by the method 535), the NM, and the WM (i.e.,dry-milled dough) is illustrated. On a percentage-by-weight basis, boththe LCM2 and the NM have bimodal distributions containing a smaller- anda larger-sized group of particles as described by their modes. Moreparticularly, the LCM2 yields a larger-sized mode (i.e., 25 mesh or 710microns with 13% weight) and a smaller-sized mode (i.e., 60 mesh or 250microns and 35% weight) appropriate for tortilla and snack making. TheNM also yields a larger-sized mode (i.e., 35 mesh or 500 microns and 30%weight) and a smaller-sized mode (i.e., 80 mesh or 180 microns and 20%weight). However, as compared to the NM dough (at ˜60%), the LCM2 doughhas a lower weight fraction (˜30%) above 45 mesh or 355 microns. Thedifference in size and weight between the larger-sized mode of the LCM2and the larger-sized mode of the NM causes the apparent peak viscosityof the LCM2 (˜3,000 centipoise) (at 95° C.) to be lower than theapparent peak viscosity of the NM (˜3,470 centipoise). This differencein apparent peak viscosity may be (at least partially) attributable to:free starch particles increasing the viscosity of the NM during pasting(i.e., at 14% solids content); and slower water diffusion into, andswelling of, the LCM2's coarser particles. Finally, the WM containssmaller and finer particles (i.e., 355 microns) than both the LCM2 andthe NM; as a result, the WM has an even higher apparent peak viscosity(˜5,600 centipoise). After two separate heating-cooling processes (i.e.,steamer 125-quencher 130 and mill 385-cooler 145), a partialgelatinization of the starchy endosperm induces resistant starch (RS3)formation (at 2.5%) along with particle-size aggregation but does notdestroy granule structure.

In an embodiment, as illustrated in FIG. 9 , yet another system adaptedto make lime-cooked masa is generally referred to by the referencenumeral 605. The system 605 includes a moisturizer 610, a conditioner615, a polisher/dehuller 620, a separator 625, a screener 630, aseparator 635, a moisturizer 640, a conditioner 645, a cooker 650, aconditioner such as, for example, a conditioner bin 655, a mill 660, anda cooler 665. As shown in FIG. 9 , the conditioner 615 is operablycoupled to the moisturizer 610. The polisher/dehuller 620 is operablycoupled to the conditioner 615. The separator 625 is operably coupled tothe polisher/dehuller 620. The screener 630 is also operably coupled tothe polisher/dehuller 620. The separator 635 is operably coupled to thescreener 630. The moisturizer 640 is operably coupled to each of theseparator 625 and the separator 635. The conditioner 645 is operablycoupled to the moisturizer 640. The cooker 650 is operably coupled toeach of the conditioner 645 and the screener 630. The conditioner bin655 is operably coupled to the cooker 650. The mill 660 is operablycoupled to the conditioner bin 655. The cooler 665 is operably coupledto the mill 660.

In operation, with continuing reference to FIG. 9 , the moisturizer 610receives clean maize kernel, as indicated by arrow 670, receives water,as indicated by arrow 675, moisturizes the received clean maize kernelwith the received water, and discharges the moisturized maize kernel, asindicated by arrow 680. The clean maize kernel includes endosperm, germ,pericarp, and tip cap components.

The conditioner 615 receives the moisturized maize kernel dischargedfrom the moisturizer 610, as indicated by the arrow 680, tempers themoisturized maize kernel, and discharges the tempered maize kernel, asindicated by arrow 685. In some embodiments, the conditioner 615includes a feeder adapted to receive the moisturized maize kerneldischarged from the moisturizer 610.

The polisher/dehuller 620 receives the tempered maize kernel dischargedfrom the conditioner 615, as indicated by the arrow 685, at leastpartially breaks and at least partially loosens the pericarp of thetempered maize kernel, discharges a coarse maize fraction including mostof the pericarp, as indicated by arrow 690, and discharges a fine maizefraction, as indicated by arrow 695. In some embodiments, thepolisher/dehuller 620 includes a feeder adapted to receive the temperedmixture from the conditioner 615.

The separator 625 receives the coarse maize fraction discharged from thepolisher/dehuller 620, as indicated by the arrow 690, receives cleanair, as indicated by arrow 691, removes the pericarp component from thecoarse maize fraction using the clean air, discharges the pericarpcomponent, as indicated by arrow 700, and discharges the purified coarsemaize fraction, as indicated by arrow 705. In some embodiments, as inFIG. 9 , the separator 625 is or includes an air separator. In someembodiments, in addition, or instead, the separator 625 is or includesanother type of separator.

The screener 630 receives the fine maize fraction discharged from thepolisher/dehuller 620, as indicated by the arrow 695, receives thepericarp component discharged from the separator 625, as indicated bythe arrow 700, screens the received maize particles to yield first,second, and third streams, discharges the first stream as a byproduct,as indicated by arrow 710, discharges the second stream, as indicated byarrow 715, and discharges the third stream, as indicated by arrow 720.The first stream includes large size pericarp. The second streamincludes residual fines, the tip cap component, and small size or finepericarp. The third stream includes purified fines.

The separator 635 receives the second stream discharged from thescreener 630, as indicated by the arrow 715, receives clean air, asindicated by arrow 725, removes the residual fines and small size orfine pericarp components from the second stream using the clean air,discharges the removed residual fines and small size or fine pericarpcomponents as a byproduct, as indicated by arrow 730, and discharges thepurified second stream, which includes the tip cap component, asindicated by arrow 735.

The moisturizer 640 receives the purified coarse maize fractiondischarged from the separator 625, as indicated by the arrow 705,receives the purified second stream discharged from the separator 635,as indicated by the arrow 735, receives water, as indicated by arrow740, moisturizes the received maize particles with the received water,and discharges the moisturized maize particles, as indicated by arrow745.

The conditioner 645 receives the moisturized maize particles dischargedfrom the moisturizer 640, as indicated by the arrow 745, tempers themoisturized maize particles, and discharges the tempered maizeparticles, as indicated by arrow 750.

The cooker 650 receives the third stream discharged from the screener630, as indicated by the arrow 720, receives the tempered maizeparticles discharged from the conditioner 645, as indicated by the arrow750, receives water, as indicated by arrow 755, receives clean steam, asindicated by arrow 760, cooks the received maize particles with thereceived water and clean steam, and discharges the cooked maizeparticles, as indicated by arrow 765. In some embodiments, as shown inFIG. 9 , the maize kernel, in the form of tempered maize particlesdischarged from the conditioner 645, is limed by adding lime to thetempered maize particles discharged from the conditioner 645, asindicated by arrow 770, before, during, or after the discharged temperedmaize particles are received by the cooker 650; in some embodiments, themaize particles are limed by adding lime powder in a range of 0.1% to0.3% based on maize kernel; in some embodiments, the maize particles arelimed before they are received by the cooker 650; in some embodiments,before the maize particles are received by the cooker 650, the maizeparticles are limed by adding lime powder in a range of 0.1% to 0.3%based on maize kernel. In some embodiments, the cooker 650 steams thereceived maize particles, the received lime, and the received water toan absolute pressure of at least, for example, 90 kPa.

The conditioner bin 655 receives the cooked maize particles dischargedfrom the cooker 650, as indicated by the arrow 765, tempers the cookedmaize particles, and discharges the tempered maize particles, asindicated by arrow 775. In some embodiments, as in FIG. 9 , water isadded to the cooked maize particles discharged from the cooker 650, asindicated by arrow 780, before, during, or after the discharged cookedmaize particles are received by the conditioner bin 655; the added waterlowers the temperature of the cooked maize particles.

The mill 660 receives the tempered maize particles from the conditionerbin 655, as indicated by the arrow 775, mills the tempered maizeparticles into lime-cooked masa, and discharges the lime-cooked masa, asindicated by arrow 785. In some embodiments, as in FIG. 9 , water isadded to the tempered maize particles discharged from the conditionerbin 655, as indicated by arrow 790, before, during, or after thedischarged tempered maize particles are received by the mill 660. Insome embodiments, the mill 660 is or includes a stone mill havingmilling stone(s) that are adjustable to various gap widths dependingupon the desired characteristics of the lime-cooked masa.

The cooler 665 receives the lime-cooked masa discharged from the mill660, as indicated by the arrow 785, receives clean air, as indicated byarrow 795, cools the lime-cooked masa with the clean air, and dischargesthe cooled lime-cooked masa, as indicated by arrow 800. The dischargedlime-cooked masa can then be used in the manufacture of food productssuch as, for example, snacks (e.g., chips) and tortillas.

In an embodiment, as illustrated in FIG. 10 , a method of makinglime-cooked masa (“LCM3”) using the system 605 is generally referred toby the reference numeral 805. In some embodiments, execution of themethod 805 results in: water consumption of from 0.52 to 0.60 partswater per one part maize kernel by weight for chip production and 0.76parts water per one part maize kernel by weight for tortilla production;negligible wastewater discharge; negligible solid waste; energyconsumption of less than 0.5 gigajoule (GJ)/ton of the provided maizekernel for chip production; or any combination thereof. In anembodiment, as illustrated in FIG. 10 , a method of making lime-cookedmasa (“LCM3”) using the system 605 is generally referred to by thereference numeral 805. In some embodiments, execution of the method 805results in: water consumption of no more than 0.60 parts water per onepart maize kernel by weight for chip production; no more than 0.76 partswater per one part maize kernel by weight for tortilla production;negligible wastewater discharge; negligible solid waste; energyconsumption of less than 0.5 gigajoule (GJ)/ton of the provided maizekernel for chip production; or any combination thereof. The method 805includes at a step 810, moisturizing, using the moisturizer 610, maizekernel by adding water to the maize kernel in a first predeterminedproportion, the maize kernel having endosperm, germ, pericarp, and tipcap components. In some embodiments of the step 810, the firstpredetermined proportion ranges from 0.07 to 0.12 parts water for every1 part of solids (i.e., maize kernel).

At a step 815, the maize kernel is conditioned, using the conditioner615, for a first predetermined amount of time to cause moistureabsorption to within a first predetermined range. In some embodiments ofthe step 815, the first predetermined amount of time is at least 10minutes. In some embodiments of the step 815, the first predeterminedrange is from 17% to 21%.

At a step 820, the maize kernel is polished/dehulled, using thepolisher/dehuller 620, to yield a fine fraction and a coarse fraction.

At a step 825, the coarse fraction is separated, using the separator625, to yield a purified coarse fraction and pericarp.

At a step 830, the fine fraction and the pericarp separated from thecoarse fraction are screened, using the screener 630, to yield first,second, and third streams, the first stream including pericarp, thesecond stream including residual fines, tip cap, and fine pericarp, andthe third stream including purified fines.

At a step 835, the second stream is separated, using the separator 635,to yield tip cap and a residual second stream.

At a step 840, the purified coarse fraction and the tip cap separatedfrom the second stream are moisturized, using the moisturizer 640, byadding water in a second predetermined proportion. In some embodimentsof the step 840, the second predetermined proportion ranges from 0.2 to0.26 parts water for every 1 part of solids.

At a step 845, the purified coarse fraction and the tip cap separatedfrom the second stream are conditioned, using the conditioner 645, for asecond predetermined amount of time to cause moisture absorption towithin a second predetermined range. In some embodiments of the step845, the second predetermined amount of time is at least 3 hours. Insome embodiments of the step 845, the second predetermined moisturerange is from 30% to 34%.

At a step 850, the purified coarse fraction, the tip cap separated fromthe second stream, and the third stream are cooked, using the cooker650, in an environment of steam. In some embodiments, before or duringthe step 850, the maize particles are limed by adding lime powder in arange of 0.1% to 0.3% based on maize kernel. In some embodiments, beforeor during the step 850, the maize particles are moisturized by addingwater in a proportion ranging from 0.20 to 0.26 parts water for every 1part of solids. In some embodiments of the step 850, the maize particlesare steamed and hydrated to an absolute pressure of at least 90 kPa foran amount of time ranging from 4 minutes to 12 minutes. During thistime, the cooker 650 reaches a temperature from 72° C. to 96° C.; as aresult, the cooked maize particles reach a moisture content from 42% to51% and a temperature from 71° C. to 89° C.

At a step 855, the maize kernel is conditioned, using the conditionerbin 655, for a third predetermined amount of time to cause moistureabsorption to within a third predetermined range. In some embodiments ofthe step 855, the third predetermined amount of time ranges from atleast 3 hours to 4 hours. In some embodiments, before or during the step855, water is added to the maize kernel in a third predeterminedproportion; for example, the third predetermined proportion may rangefrom 0.1 to 0.2 parts water for every 1 part of solids. In someembodiments, execution of the step 855 lowers the temperature of themaize particles to between 60° C. and 70° C. In some embodiments,execution of the step 855 results in the cooked maize particles reachinga moisture content from 43% to 53%.

At a step 860, the maize kernel is milled using the mill 660. In someembodiments, before or during the step 860, the method 805 furtherincludes adding water to the maize kernel in a fourth predeterminedproportion; for example, the fourth predetermined proportion may rangefrom 0.01 to 0.05 parts water for every 1 part of solids. In someembodiments, after the step 860, the method 805 further includescooling, using the cooler 665, the milled maize kernel. In someembodiments, execution of the step 860 causes the maize particles toreach a temperature of between 55° C. and 72° C. The cooler 665 maysubsequently be utilized to cool the maize particles to a temperature ofbetween 25° C. and 35° C.

Referring to FIG. 11 , a table comparing water and energy consumptionbetween traditional masa production and lime-cooked masa prepared usingone embodiment of a system of the present disclosure (e.g., LCM1prepared using the system 100, LCM2 prepared using the system 370, orLCM3 prepared using the system 605), and/or using one embodiment of amethod of the present disclosure (e.g., LCM1 prepared by the method 305,LCM2 prepared by the method 535, or LCM3 prepared by the method 805) isillustrated. As shown in FIG. 11 , it is possible to manufacturelime-cooked masa with steam heating and without wastewater (or verylittle wastewater, or negligible amounts of wastewater), and withnegligible solid waste, which is more energy and water efficient,wherein some of the nutrient, water and energy losses that would havebeen present but for the features of the present method(s) areprevented. In some embodiments, the steps of the method(s) 305, 535,and/or 805 are: continuously and repeatedly performed; continuously andrepeatedly performed for a predetermined amount of time; and/orcontinuously and repeatedly performed over a time period. In someembodiments, the operation of the system 100, 370, or 605, and/or theexecution of the method 305, 535, or 805: saves water usage; eliminateswastewater discharge; results in very little wastewater discharge;results in negligible wastewater discharge; results in savings of 91% to93% in water consumption (e.g., to between 4.5 and 5.5 cubic meters ofwater per ton of maize kernel) as compared to a traditional NM wet-mill;results in savings of 20% to 40% in energy consumption (e.g., to between0.1 and 0.2 MMBTU/ton of maize kernel) as compared to a traditional NMwet-mill; and/or reduces carbon dioxide emission (e.g., to between 60and 84 kg of CO₂/ton of maize kernel). In some embodiments, the term“ton” may refer to “metric ton,” a unit of weight equal to 1,000 kg(about 2,200 lb).

Referring to FIG. 12 , in an embodiment, a computing node 1000 forimplementing one or more embodiments of one or more of theabove-described elements, systems (e.g., 100, 370, and/or 605), methods(e.g., 305, 535, and/or 805) and/or steps (e.g., 310, 315, 320, 325,330, 335, 340, 345, 350, 355, 360, 365, 540, 545, 550, 555, 560, 565,570, 575, 580, 585, 590, 595, 600, 810, 815, 820, 825, 830, 835, 840,845, 850, 855, and/or 860), or any combination thereof, is depicted. Thenode 1000 includes a processor or microprocessor 1000 a, an input device1000 b, a storage device 1000 c, a controller 1000 d, a system memory1000 e, a display 1000 f, and a communication device 1000 g allinterconnected by one or more buses 1000 h. In several embodiments, thestorage device 1000 c may include a floppy drive, hard drive, CD-ROM,optical drive, any other form of storage device or any combinationthereof. In several embodiments, the storage device 1000 c may include,and/or be capable of receiving, a floppy disk, CD-ROM, DVD-ROM, or anyother form of computer-readable medium that may contain executableinstructions. In several embodiments, the communication device 1000 gmay include a modem, network card, or any other device to enable thenode 1000 to communicate with other nodes. In several embodiments, anynode represents a plurality of interconnected (whether by intranet orInternet) computer systems, including without limitation, personalcomputers, mainframes, PDAs, smartphones and cell phones.

In several embodiments, one or more of the components of any of theabove-described systems include at least the node 1000 and/or componentsthereof, and/or one or more nodes that are substantially similar to thenode 1000 and/or components thereof. In several embodiments, one or moreof the above-described components of the node 1000 and/or theabove-described systems include respective pluralities of samecomponents.

In several embodiments, a computer system typically includes at leasthardware capable of executing machine readable instructions, as well asthe software for executing acts (typically machine-readableinstructions) that produce a desired result. In several embodiments, acomputer system may include hybrids of hardware and software, as well ascomputer sub-systems.

In several embodiments, hardware generally includes at leastprocessor-capable platforms, such as client-machines (also known aspersonal computers or servers), and hand-held processing devices (suchas smart phones, tablet computers, personal digital assistants (PDAs),or personal computing devices (PCDs), for example). In severalembodiments, hardware may include any physical device that is capable ofstoring machine-readable instructions, such as memory or other datastorage devices. In several embodiments, other forms of hardware includehardware sub-systems, including transfer devices such as modems, modemcards, ports, and port cards, for example.

In several embodiments, software includes any machine code stored in anymemory medium, such as RAM or ROM, and machine code stored on otherdevices (such as floppy disks, flash memory, or a CD ROM, for example).In several embodiments, software may include source or object code. Inseveral embodiments, software encompasses any set of instructionscapable of being executed on a node such as, for example, on a clientmachine or server.

In several embodiments, combinations of software and hardware could alsobe used for providing enhanced functionality and performance for certainembodiments of the present disclosure. In an embodiment, softwarefunctions may be directly manufactured into a silicon chip. Accordingly,it should be understood that combinations of hardware and software arealso included within the definition of a computer system and are thusenvisioned by the present disclosure as possible equivalent structuresand equivalent methods.

In several embodiments, computer readable mediums include, for example,passive data storage, such as a random-access memory (RAM) as well assemi-permanent data storage such as a compact disk read only memory(CD-ROM). One or more embodiments of the present disclosure may beembodied in the RAM of a computer to transform a standard computer intoa new specific computing machine. In several embodiments, datastructures are defined organizations of data that may enable anembodiment of the present disclosure. In an embodiment, data structuremay provide an organization of data, or an organization of executablecode.

In several embodiments, any networks and/or one or more portionsthereof, may be designed to work on any specific architecture. In anembodiment, one or more portions of any networks may be executed on asingle computer, local area networks, client-server networks, wide areanetworks, internets, hand-held and other portable and wireless devicesand networks.

In several embodiments, a database may be any standard or proprietarydatabase software. In several embodiments, the database may have fields,records, data, and other database elements that may be associatedthrough database specific software. In several embodiments, data may bemapped. In several embodiments, mapping is the process of associatingone data entry with another data entry. In an embodiment, the datacontained in the location of a character file can be mapped to a fieldin a second table. In several embodiments, the physical location of thedatabase is not limiting, and the database may be distributed. In anembodiment, the database may exist remotely from the server, and run ona separate platform. In an embodiment, the database may be accessibleacross the Internet. In several embodiments, more than one database maybe implemented.

In several embodiments, a plurality of instructions stored on anon-transitory computer readable medium may be executed by one or moreprocessors to cause the one or more processors to carry out or implementin whole or in part the above-described operation of each of theabove-described elements, systems (e.g., 100, 370, and/or 605), methods(e.g., 305, 535, and/or 805), steps (e.g., 310, 315, 320, 325, 330, 335,340, 345, 350, 355, 360, 365, 540, 545, 550, 555, 560, 565, 570, 575,580, 585, 590, 595, 600, 810, 815, 820, 825, 830, 835, 840, 845, 850,855, and/or 860), or any combination thereof. In several embodiments,such a processor may include one or more of the microprocessor 1000 a,any processor(s) that are part of the components of the above-describedsystems, and/or any combination thereof, and such a computer readablemedium may be distributed among one or more components of theabove-described systems. In several embodiments, such a processor mayexecute the plurality of instructions in connection with a virtualcomputer system. In several embodiments, such a plurality ofinstructions may communicate directly with the one or more processors,and/or may interact with one or more operating systems, middleware,firmware, other applications, and/or any combination thereof, to causethe one or more processors to execute the instructions. In severalembodiments, such a non-transitory computer readable medium may be partof one or more controllers; in several embodiments, the system 100, 370,or 605 may include such one or more controllers, in several embodiments,one or more components of the system 100, 370, or 605 may include suchone or more controllers.

In some embodiments, objects and advantages of the present disclosurecan be achieved through a continuous processing technique applied to theproduction of whole lime-cooked masa, in which heating and cooling stepsincrease the resistant starch, and the lime cooked hull yields a solublefiber that can bind calcium. Embodiments of this process includeproviding a clean maize kernel by mixing and conditioning with limesolution, steaming the tempered kernel with saturated steam to effect apartial cooking without wastewater and reduced energy usage,conditioning and cooling the blanched kernel for efficient grinding,milling and adding water to the tempered kernel so as to produce acoarse-ground and fine-ground dough material in order to yield awasteless lime-cooked masa, forming the masa into the desired productform, such as tortilla or snack, baking and cooling the food product,and packaging the tortilla, or further baking or frying the food forsnack and maize-based foods.

In some embodiments, objects and advantages of the present disclosurecan be achieved through a continuous processing technique applied to theproduction of partially whole lime-cooked masa, in which the hull isseparated while leaving the tip cap. Embodiments of this process includeproviding a clean maize kernel by mixing and conditioning with limesolution, steaming the tempered kernel with saturated steam to effect apartial cooking without wastewater and reduced energy usage,conditioning and cooling the steamed kernel for efficient grinding,crushing the kernel, separating a hull fraction from the ground kernel,milling and adding water to the separated fraction so as to produce acoarse-ground and fine-ground dough material in order to yield awasteless lime-cooked masa, forming the masa into the desired productform, such as tortilla or snack, baking and cooling the food product,and packaging the tortilla or further baking or frying the food forsnack and maize-based foods.

The present disclosure introduces a method of making lime-cooked masa.The method generally includes: providing maize kernel having endosperm,germ, pericarp, and tip cap components; after providing the maizekernel, adding water to the maize kernel in a first predeterminedproportion, and conditioning, using a first conditioner, the maizekernel for a first predetermined amount of time to cause moistureabsorption to within a first predetermined range; liming the maizekernel; cooking, using a cooker, the maize kernel in an environment ofsteam; after cooking the maize kernel, adding water to the maize kernelin a second predetermined proportion, and conditioning, using a secondconditioner, the maize kernel for a second predetermined amount of timeto cause moisture absorption to within a second predetermined range; andmilling, using one or more mills, the maize kernel.

The foregoing method embodiment may include one or more of the followingelements, either alone or in combination with one another:

Execution of the method results in: water consumption of no more than0.6 parts of water per one part of maize kernel by weight for chipproduction; water consumption of no more than 0.76 parts of water perone part of maize kernel by weight for tortilla production; negligiblewastewater discharge; negligible solid waste; energy consumption of lessthan 0.5 GJ/ton of the provided maize kernel for chip production; or anycombination thereof.

The method further includes: after milling the maize kernel, cooling,using a cooler, the milled maize kernel; and after cooling the milledmaize kernel, kneading, using a kneader, the cooled milled maize kernelinto the lime-cooked masa.

The method further includes: before or during milling the maize kernel,adding water to the maize kernel in a third predetermined proportion.

The method further includes: after conditioning the maize kernel for thefirst predetermined amount of time and before cooking the maize kernel,polishing/dehulling, using a polisher/dehuller, the maize kernel toyield a fine fraction and a coarse fraction, separating, using a firstseparator, the coarse fraction to yield a purified coarse fraction andpericarp, screening, using a screener, the fine fraction and thepericarp separated from the coarse fraction to yield first, second, andthird streams, the first stream including pericarp, the second streamincluding residual fines, tip cap, and fine pericarp, and the thirdstream including purified fines, and separating, using a secondseparator, the second stream to yield tip cap and a residual secondstream.

The method further includes: adding water to the purified coarsefraction and the tip cap separated from the second stream in a thirdpredetermined proportion; and conditioning, using a third conditioner,the purified coarse fraction and the tip cap separated from the secondstream for a third predetermined amount of time to cause moistureabsorption to within a third predetermined range.

Cooking, using the cooker, the maize kernel in the environment of steamincludes: after conditioning the purified coarse fraction and the tipcap separated from the second stream for the third predetermined amountof time, cooking, using the cooker, the purified coarse fraction, thetip cap separated from the second stream, and the third stream in theenvironment of steam; and liming the maize kernel includes: adding limepowder to the purified coarse fraction and the tip cap separated fromthe second stream.

The method further includes: after conditioning the maize kernel for thesecond predetermined amount of time and before milling the maize kernel,crushing, using a crusher, the maize kernel into coarse-ground kerneland pericarp, and separating, using a separator, the crushed maizekernel to yield the coarse-ground kernel and the pericarp.

Milling, using the one or more mills, the maize kernel includes: afterseparating the crushed maize kernel to yield the coarse-ground kerneland the pericarp, milling, using the one or more mills, thecoarse-ground kernel.

Milling, using the one or more mills, the maize kernel includes: millinga first portion of the maize kernel with a first mill to yieldfine-ground dough material; and milling a second portion of the maizekernel with a second mill to yield coarse-ground dough material.

The present disclosure also introduces a system adapted to makelime-cooked masa. The system generally includes: a first conditioner towhich water and maize kernel are adapted to be provided in a firstpredetermined proportion, the maize kernel having endosperm, germ,pericarp, and tip cap components, wherein the first conditioner isadapted to condition the maize kernel for a first predetermined amountof time to cause moisture absorption to within a first predeterminedrange; a cooker adapted to cook the maize kernel together with lime inan environment of steam; a second conditioner to which water and thecooked maize kernel are adapted to be provided in a second predeterminedproportion, wherein the second conditioner is adapted to condition thecooked maize kernel for a second predetermined amount of time to causemoisture absorption within a second predetermined range; and one or moremills adapted to mill the maize kernel.

The foregoing system embodiment may include one or more of the followingelements, either alone or in combination with one another:

Using the system to make lime-cooked masa results in: water consumptionof no more than 0.6 parts of water per one part of maize kernel byweight for chip production; water consumption of no more than 0.76 partsof water per one part of maize kernel by weight for tortilla production;negligible wastewater discharge; negligible solid waste; energyconsumption of less than 0.5 GJ/ton of the provided maize kernel forchip production; or any combination thereof.

The system further includes: a cooler adapted to cool the milled maizekernel; and a kneader adapted to knead the cooled maize kernel into thelime-cooked masa.

Water and the maize kernel are adapted to be provided to the one or moremills in a third predetermined proportion.

The system further includes: a polisher/dehuller adapted topolish/dehull the maize kernel to yield a fine fraction and a coarsefraction; a first separator adapted to separate the coarse fraction toyield a purified coarse fraction and pericarp; a screener adapted toscreen the fine fraction and the pericarp separated from the coarsefraction to yield first, second, and third streams, the first streamincluding pericarp, the second stream including residual fines, tip cap,and fine pericarp, and the third stream including purified fines; and asecond separator adapted to separate the second stream to yield tip capand a residual second stream.

Water, the purified coarse fraction, and the tip cap separated from thesecond stream are adapted to be provided to a third conditioner in athird predetermined proportion; and the system further includes thethird conditioner adapted to condition the purified coarse fraction andthe tip cap separated from the second stream for a third predeterminedamount of time to cause moisture absorption to within a thirdpredetermined range.

The cooker is adapted to cook the purified coarse fraction, the tip capseparated from the second stream, and the third stream in theenvironment of steam.

The system further includes: a crusher adapted to crush the maize kernelinto coarse-ground kernel and pericarp; and a separator adapted toseparate the crushed maize kernel to yield the coarse-ground kernel andthe pericarp.

The one or more mills are adapted to mill the coarse-ground kernel.

The one or more mills include: a first mill adapted to mill a firstportion of the maize kernel to yield fine-ground dough material; and asecond mill adapted to mill a second portion of the maize kernel toyield coarse-ground dough material.

The present disclosure also introduces an apparatus, which generallyincludes: a non-transitory computer readable medium; and a plurality ofinstructions stored on the non-transitory computer readable medium,wherein the instructions are executed with one or more processors sothat the following steps are executed: adding water to maize kernel in afirst predetermined proportion, the maize kernel having endosperm, germ,pericarp, and tip cap components; conditioning, using a firstconditioner, the maize kernel for a first predetermined amount of timeto cause moisture absorption to within a first predetermined range;liming the maize kernel; cooking, using a cooker, the maize kernel in anenvironment of steam; after cooking the maize kernel, adding water tothe maize kernel in a second predetermined proportion, and conditioning,using a second conditioner, the maize kernel for a second predeterminedamount of time to cause moisture absorption to within a secondpredetermined range; and milling, using one or more mills, the maizekernel.

The foregoing apparatus embodiment may include one or more of thefollowing elements, either alone or in combination with one another:

Execution of the instructions with the one or more processors resultsin: water consumption of no more than 0.6 parts of water per one part ofmaize kernel by weight for chip production; water consumption of no morethan 0.76 parts of water per one part of maize kernel by weight fortortilla production; negligible wastewater discharge; negligible solidwaste; energy consumption of less than 0.5 GJ/ton of the provided maizekernel for chip production; or any combination thereof.

The instructions are executed with the one or more processors so thatthe following additional steps are executed: after milling the maizekernel, cooling, using a cooler, the milled maize kernel; and aftercooling the maize kernel, kneading, using a kneader, the cooled maizekernel into the lime-cooked masa.

The instructions are executed with the one or more processors so thatthe following additional step is executed: before or during milling themaize kernel, adding water to the maize kernel in a third predeterminedproportion.

The instructions are executed with the one or more processors so thatthe following additional steps are executed: after conditioning themaize kernel for the first predetermined amount of time and beforecooking the maize kernel, polishing/dehulling, using apolisher/dehuller, the maize kernel to yield a fine fraction and acoarse fraction, separating, using a first separator, the coarsefraction to yield a purified coarse fraction and pericarp, screening,using a screener, the fine fraction and the pericarp separated from thecoarse fraction to yield first, second, and third streams, the firststream including pericarp, the second stream including residual fines,tip cap, and fine pericarp, and the third stream including purifiedfines, and separating, using a second separator, the second stream toyield tip cap and a residual second stream.

The instructions are executed with the one or more processors so thatthe following additional steps are executed: adding water to thepurified coarse fraction and the tip cap separated from the secondstream in a third predetermined proportion; and conditioning, using athird conditioner, the purified coarse fraction and the tip capseparated from the second stream for a third predetermined amount oftime to cause moisture absorption to within a third predetermined range.

Cooking, using the cooker, the maize kernel in the environment of steamincludes: after conditioning the purified coarse fraction and the tipcap separated from the second stream for the third predetermined amountof time, cooking, using the cooker, the purified coarse fraction, thetip cap separated from the second stream, and the third stream in theenvironment of steam; and liming the maize kernel includes: adding limepowder to the purified coarse fraction and the tip cap separated fromthe second stream.

The instructions are executed with the one or more processors so thatthe following additional steps are executed: after conditioning themaize kernel for the second predetermined amount of time and beforemilling the maize kernel, crushing, using a crusher, the maize kernelinto coarse-ground kernel and pericarp, and separating, using aseparator, the crushed maize kernel to yield the coarse-ground kerneland the pericarp.

Milling, using the one or more mills, the maize kernel includes: afterseparating the crushed maize kernel to yield the coarse-ground kerneland the pericarp, milling, using the one or more mills, thecoarse-ground kernel.

Milling, using the one or more mills, the maize kernel includes: millinga first portion of the maize kernel with a first mill to yieldfine-ground dough material; and milling a second portion of the maizekernel with a second mill to yield coarse-ground dough material.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the present disclosure.

In some embodiments, the elements and teachings of the variousembodiments may be combined in whole or in part in some or all of theembodiments. In addition, one or more of the elements and teachings ofthe various embodiments may be omitted, at least in part, and/orcombined, at least in part, with one or more of the other elements andteachings of the various embodiments.

Any spatial references, such as, for example, “upper,” “lower,” “above,”“below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,”“upwards,” “downwards,” “side-to-side,” “left-to-right,”“right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,”“bottom-up,” “top-down,” etc., are for the purpose of illustration onlyand do not limit the specific orientation or location of the structuredescribed above.

In some embodiments, while different steps, processes, and proceduresare described as appearing as distinct acts, one or more of the steps,one or more of the processes, and/or one or more of the procedures mayalso be performed in different orders, simultaneously and/orsequentially. In some embodiments, the steps, processes, and/orprocedures may be merged into one or more steps, processes and/orprocedures.

In some embodiments, one or more of the operational steps in eachembodiment may be omitted. Moreover, in some instances, some features ofthe present disclosure may be employed without a corresponding use ofthe other features. Moreover, one or more of the above-describedembodiments and/or variations may be combined in whole or in part withany one or more of the other above-described embodiments and/orvariations.

Although some embodiments have been described in detail above, theembodiments described are illustrative only and are not limiting, andthose skilled in the art will readily appreciate that many othermodifications, changes and/or substitutions are possible in theembodiments without materially departing from the novel teachings andadvantages of the present disclosure. Accordingly, all suchmodifications, changes, and/or substitutions are intended to be includedwithin the scope of this disclosure as defined in the following claims.Moreover, it is the express intention of the applicant not to invoke 35U.S.C. § 112, paragraph 6, for any limitations of any of the claimsherein, except for those in which the claim expressly uses the word“means” together with an associated function.

What is claimed is:
 1. A method comprising: (a) moisturizing a maizekernel to produce a moisturized maize kernel, wherein the step (a)comprises spraying the maize kernel with a lime solution; (b) temperingthe moisturized maize kernel, using a conditioner, to produce a temperedmaize kernel; (c) after the step (b), receiving, by a cooker and fromthe conditioner, the tempered maize kernel; (d) steaming, using thecooker, the tempered maize kernel; (e) tempering the steamed maizekernel produced by the step (d); (f) grinding a first portion of thetempered maize kernel produced by the step (e) into a fine-ground doughmaterial using a first mill; (g) grinding a second portion of thetempered steamed maize kernel produced by the step (e) into acoarse-ground dough material using a second mill, wherein the first millis different from the second mill; (h) cooling the fine-ground doughmaterial produced by the step (f) and the coarse-ground dough materialproduced by the step (g); and (i) mixing the cooled fine-ground doughmaterial and the cooled coarse-ground dough material to form lime-cookedmasa; wherein the lime-cooked masa comprises the coarse-ground dough andthe fine-ground dough.
 2. The method of claim 1, wherein the moisturizedfirst maize kernel is tempered for 20 to 40 minutes.
 3. The method ofclaim 2, wherein the tempered first maize kernel is steamed for 5 to 10minutes.
 4. The method of claim 1, wherein the first mill comprises afirst stone mill having a first stone gap; and wherein the second millcomprises a second stone mill having a second stone gap that isdifferent from the first stone gap.
 5. A method comprising: (a)moisturizing a maize kernel; (b) tempering the moisturized maize kernelproduced by the step (a); (c) polishing/dehulling the tempered maizekernel produced by the step (b) to yield a first portion of the maizekernel and a second portion of the maize kernel; wherein the secondportion comprises a fine maize fraction; (d) moisturizing the firstportion of the maize kernel to produce a first moisturized portion; (e)tempering the first moisturized portion, using a conditioner, to producea first tempered portion; (f) after the step (e), receiving, in a cookerand from the conditioner, the first tempered portion; (g) receiving, inthe cooker, the fine maize fraction; wherein the fine maize fractionbypasses the steps (d) and (e) before being received in the cooker atthe step (g); and (h) steaming, using the cooker, the first temperedportion and the fine maize fraction.
 6. The method of claim 5, whereinthe first moisturized portion is tempered for at least three hoursduring the step (e).
 7. The method of claim 6, wherein the firsttempered portion and the fine maize fraction are steamed for 4 minutesto 12 minutes during the step (h).
 8. The method of claim 5, wherein themaize kernel is sprayed with the lime solution for 5 to 10 minutes. 9.The method of claim 5, wherein the lime solution comprises between 1%and 5% lime by weight.
 10. The method of claim 5, (i) moisturizing thesteamed portion produced by the step (h) for at least 3 hours to 4hours; and (j) milling the moisturized portion produced by the step (i).11. The method of claim 5, wherein the first tempered portion comprisesa coarse fraction and a tip cap component.
 12. The method of claim 11,further comprising adding lime powder to the first tempered portion.